Apparatus and method for management of harvest residue

ABSTRACT

A stalk roll assembly for header of a combine harvester. The assembly includes first and second stalk rolls spaced laterally with respect to one another and rotating in opposite directions. Each stalk roll includes a frusto-conical nose and a cylindrical body. The cylindrical body includes a plurality of radially extending flutes. The nose includes a pair of helical flights. The plurality of flutes includes at least one cutting flute having a straight edge and a plurality of puncturing flutes with teeth. The stalk rolls are laterally offset a distance that permits the tips of the flutes to laterally overlap and the teeth of the puncturing flutes are longitudinally offset so the tips of the teeth are received between with the valleys of the teeth of the other stalk roll.

CROSS-REFERENCE TO RELATED APPLICATIONS

This application is a continuation of U.S. patent Ser. No. 15/655,657filed Jul. 20, 2017 which is a continuation of International PatentApplication No. PCT/US2016/014177, filed Jan. 20, 2016, which claims thebenefit of U.S. Provisional Application No. 62/203,370, filed Aug. 10,2015 and U.S. Provisional Application No. 62/105,252, filed Jan. 20,2015. Each of the above-referenced applications are incorporated hereinby reference in their entireties.

BACKGROUND

Modern conventional agricultural combine harvesters or “combines”utilize removable and interchangeable attachments called “headers” or“heads” which are adapted for harvesting different types of crops. Anexample of a conventional combine 10 is shown in FIGS. 1 and 2 with aconventional header attachment 20 used for harvesting corn (i.e., a“cornhead” or “cornheader”). The conventional cornheader 20 includes aplurality of conical crop divider points 22 (“points” or “snouts”) whichextend forwardly and diverge rearwardly. Row unit assemblies 30 aredisposed between the adjacent points where the rearwardly divergingpoints 22 nearly converge. In FIG. 1, a cornhead 20 is illustrated withtwelve row unit assemblies 30 (i.e., a 12-row cornhead) but it should beunderstood that cornhead sizes typically range from four rows totwenty-four rows or more.

As illustrated in FIG. 3, during harvesting operations, the combine 10is positioned with the points 22 of the cornhead 20 positioned betweenadjacent corn rows 12 and below the ears 14 on the cornstalks 16. Itshould be appreciated that as the combine 10 drives forwardly throughthe field as indicated by the arrow 18 in FIG. 2, the conical,rearwardly diverging shape of the points 22 causes the cornstalks 16within each row 12 to be guided and directed into the row unitassemblies 30 between the adjacent points 22. As explained in moredetail below, the row unit assemblies 30 separate the ears 14 from thecornstalks 16 and convey the separated ears toward the cross-auger 24.The cross-auger 24 augers the separated ears 14 toward the opening 27 ofthe feederhouse 26 in the middle of the cornheader 20. The feederhouse26 conveys the ears 14 into the interior of the combine where the cornkernels are separated from the corncob. The separated kernels then passover a series of screens which separates unwanted crop material andother residue from the kernels. The clean grain is then carried byelevators to a clean grain holding tank while the corncobs, leaves,husks and cornstalks which entered the combine are chopped anddischarged through the rear of the combine and mix with the cornstalksthat pass under the combine.

Referring to FIGS. 4-6, each row unit 20 includes a pair gatheringchains 32, 34 with outwardly extending lugs 36. The gathering chains 32,34 extend around drive sprockets 38 and idler sprockets 39 (FIG. 5).Rotation of the drive sprockets 38 causes the gathering chains 32, 34 torotate in adjacent parallel paths such that as the combine 10 drivesforwardly through the field, the outwardly extending lugs 36 draw thecornstalks 16 into the row unit 30. Below the rotating gathering chainsis a pair of spaced stripper plates 40, 42. The stripper plates 40, 42are spaced sufficiently apart to define a gap 44 between them which issufficiently wide to permit the corn stalks 16 to enter but which issufficiently narrow so that the corn ears 14 cannot pass through. A pairof rapidly rotating stalk rolls 50, 52 are positioned below stripperplates 40, 42.

As best illustrated in FIG. 6, during harvesting operations, therotating stalk rolls 50, 52 rapidly pull the corn stalks 16 downwardlythrough the gap 44 between the stripper plates 40, 42 such that when thecorn ears 14 engage the stripper plates 40, 42, the ears 14 are pulledor stripped from the cornstalks 16. Ideally, as the stalk rolls 50, 52rotate, the entire cornstalk 16 is pulled downwardly through the gap 44and is returned to the field below the header 20 as the combine drivesforwardly (FIG. 2). It should be appreciated that if the cornstalk snapsor breaks prior to ear separation or after ear separation such that theentire cornstalk is not pulled through the gap 44, the amount of plantmaterial entering the feederhouse 26 will increase, requiring morehorsepower and thus more fuel consumption. The stripped ears 14 whichremain on the stripper plates 40, 42 after the cornstalk 16 is pulledthrough the gap 44 are then conveyed by the lugs 36 of the gatheringchains 32, 34 upwardly and rearwardly to the cross-auger 24. Thecross-auger 24 augers the ears 14 to the feederhouse 26, and thefeederhouse 26 feeds the ears 14 into the interior of the combine forshelling and separating the kernels from the corncob as is known in theart.

While conventional stalk rolls generally serve their intended purpose topull and strip the ears from the cornstalks, conventional stalks rollsdo not achieve the necessary throughput of crop material when harvestingat higher speeds. Conventional stalk rolls typically have a tapered noseportion and a cylindrical body portion. The nose portion is typicallyfitted with auger flights while the cylindrical portion has a pluralityof horizontal flutes that run parallel to the axis of the stalk rollwith the flute profile co-radial with the cylindrical portion. In use,as illustrated in FIG. 6, as the stalk rolls rotate, the auger flightson the nose draw the cornstalks towards the cylindrical body. Once thecornstalk is between the cylindrical bodies of the adjacent stalk rollsthe horizontal flutes crush the cornstalks and pull the cornstalksdownwardly through the stripper plates 40, 42 as previously described.It has been found that the transition point between the auger flights onthe nose and the horizontal flutes on the cylindrical body of the stalkroll often restricts the throughput of the cornstalks, such that thecornstalks seam to hesitate or fail to advance, or even bind, at thistransition point despite the rotation of the auger flights and forwardadvancement of the combine. If the cornstalks stall at this transitionpoint, the gathering chains may snap off or break off the cornstalkcausing a large portion of the cornstalk to be pulled into thecornheader and fed into the combine rather than the stripped cornstalkpassing under the cornheader as previously described. Additionally, ifthe cornstalk is snapped off prematurely or whipped around by the stalkrolls, the corn ears can be flung from the stalk and land on the groundand not be harvested.

Second, some stalk rolls do not effectively cut and crush the cornstalk,thereby leaving long sections of the cornstalk intact and not cut andcrushed in more than one direction with respect to the axis of thecornstalk. These long sections decompose very slowly, limiting theirpotential benefit to subsequent crops. Still other stalk rolls chop andcrush the cornstalks so finely, as to potentially create a negativeimpact on soil microbial activity which can negatively affect the nextseason's crop. For example, the cornstalks that are cut and crushed andpass under the cornheader, together with the unwanted corncobs, husksand leaves that passes through and are discharged by the combine, i.e.,the crop residue—commonly called corn stover—has a carbon to nitrogen toratio of 57:1. When the stover is chopped to small pieces, soil microbeswill quickly work to decompose the stover. This relatively rapiddecomposition forces the microbes to find additional nitrogen to go withthe excess carbon to consume the stover because it contains a greaterproportion of carbon to nitrogen. The soil microbes then tie up anyexcess nitrogen available in the soil, called immobilization, creating adeficit of nitrogen in the soil, which nitrogen deficit can extend intothe next crop season thereby negatively affecting the critical earlygrowth stages of the next season's crop. This condition may persistuntil the beneficial soil microbes die, decompose, and release nitrogen(mineralization) contained in their bodies, or some other source ofnitrogen becomes available in the soil.

Third, some stalk rolls are not designed to crush and cut varyingcornstalk diameters. For example, cornstalks have a larger diameter attheir base near the root system and the diameter decreases along thelength of the cornstalk toward the tassel. It is important that theentire cornstalk length be crushed and cut to the appropriate residuesize to aid in decomposition.

Accordingly, there is a need for a stalk roll which allows for highthroughput of plant material, which crushes the cornstalks in more thanone direction and is capable of chopping cornstalks of varying diametersacross the field and of varying diameters along the length of thecornstalks to aid decomposition in the field.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a front elevation view of an embodiment of a modernconventional agricultural combine harvester with a cornhead attachment.

FIG. 2 is a side elevation view of the combine harvester and cornhead ofFIG. 1.

FIG. 3 is the same front elevation view of the combine harvester andcornhead of FIG. 1, but shown in a cornfield in harvesting position.

FIG. 4 is an enlarged view of the portion of the cornheader circled inFIG. 1 showing parts of the row unit assembly between the crop dividerpoints.

FIG. 5 is a perspective view of a row unit assembly.

FIG. 6 is a partial front elevation view of a row unit assembly inoperation.

FIG. 7 is a front perspective view of an embodiment of a stalk rollassembly comprising first and second stalk rolls.

FIG. 8 is a top plan view of the stalk roll assembly of FIG. 7.

FIG. 9 is an enlarged view of the circled area of FIG. 8 showing theteeth meshing as they rotate past one another.

FIG. 10 is a front perspective view of an embodiment of one of the stalkrolls comprising the stalk roll assembly of FIG. 7.

FIG. 11 is a rear perspective view of the stalk roll of FIG. 10.

FIG. 12 is a front elevation view of the stalk roll of FIG. 10.

FIG. 13 is a rear elevation view of the stalk roll of FIG. 10.

FIG. 14 is a side elevation view of the stalk roll of FIG. 11.

FIG. 15 is a top plan view of the stalk roll of FIG. 11.

FIG. 16 is a cross-sectional perspective view of the stalk roll of FIG.10 as viewed along lines 16-16 of FIG. 10.

FIG. 17 is a front perspective view of an embodiment of the other stalkroll comprising the stalk roll assembly of FIG. 7.

FIG. 18 is a rear perspective view of the stalk roll of FIG. 17.

FIG. 19 is a front elevation view of the stalk roll of FIG. 17.

FIG. 20 is a rear elevation view of the stalk roll of FIG. 17.

FIG. 21 is a side elevation view of the stalk roll of FIG. 18.

FIG. 22 is a top plan view of the stalk roll of FIG. 18.

FIG. 23 is a cross-sectional perspective view of the stalk roll of FIG.18 as viewed along lines 23-23 of FIG. 18.

FIGS. 24-26 illustrate the stalk roll assembly of FIG. 7 as the stalkrolls rotate through a cornstalk.

FIG. 27 illustrates another embodiment of a stalk roll assemblycomprising first and second stalk rolls.

FIG. 28 is a front perspective view of the left stalk roll as viewed inFIG. 27.

FIG. 29 is a rear perspective view of the left stalk roll of FIG. 28.

FIG. 30 is a rear elevation view of the left stalk roll of FIG. 28.

FIG. 31 is a front elevation view of the left stalk roll of FIG. 28.

FIG. 32 is a front perspective view of the right stalk roll as viewed inFIG. 27.

FIG. 33 is a rear perspective view of the left stalk roll of FIG. 32.

FIG. 34 is a rear elevation view of the left stalk roll of FIG. 32.

FIG. 35 is a front elevation view of the left stalk roll of FIG. 32.

DESCRIPTION

Referring to the drawings wherein like reference numerals designate thesame or corresponding parts throughout the several views of thedrawings, FIG. 7 shows an embodiment of a stalk roll assembly 100comprising first and second adjacently spaced stalk rolls 200, 300 whichmay form part of a row unit 30 of an original equipment manufacturer(OEM) or as a replacement stalk roll assembly for purposes ofretrofitting an OEM row unit 30. FIG. 8 is a top plan view of the stalkroll assembly 100 of FIG. 7. The stalk rolls 200, 300 are removablysecured in a conventional manner to drive shafts (not shown) whichextend forwardly from a frame member 31 of the row unit assembly 30. Itshould be appreciated that the configuration of the drive shafts andmanner of attachment to the drive shafts may vary between makes andmodels of combine headers as recognized and understood by those of skillin the art.

In operation, each of the stalk rolls 200, 300 rotate about theirrespective longitudinal X-X axis in the direction indicated by arrow120. As will be described in detail later, each of the stalk rolls 200,300 has a slightly different configuration which cooperate to achievehigh throughput of the cornstalks, leaves, husks, etc., while alsoensuring that the cornstalks are crushed along their length in more thanone direction and chopped in lengths preferably between six to eightinches in length.

Each of the stalk rolls 200, 300 is illustrated and described separatelybelow, but first, the common features of both stalk rolls are describedtogether with reference numerals in the 200 -series referring to thefeature of the first stalk roll 200 and reference numerals in the300-series referring to the features of the second stalk roll 300.

Each stalk roll 200, 300 has a frusto-conical nose 202, 302 whichtransitions into an elongated substantially cylindrical body 204, 304.The nose 202, 302 includes a pair of flights 206, 208 and 306, 308 whichextend helically rearwardly toward the cylindrical body 204, 304. Itshould be appreciated that the helical direction of the flights of therespective stalk rolls are opposite one another such that when the stalkrolls 200, 300 rotate in the direction indicated by arrows 120, theflights will cooperate to draw the cornstalks rearwardly toward andbetween the cylindrical bodies 204, 304 of the adjacently disposed stalkrolls 200, 300.

Each cylindrical body 204, 304 includes a plurality of flutes 210, 310extending radially outwardly and spaced equidistantly around thecircumference of the body 204, 304 and which extend along the length ofthe body 204, 304 in substantially parallel relation. The flutes 210,310 are wide at their base 212, 312 and get progressively narrower asthey curve or hook toward the outer edge 214, 314 resulting in concavesurface 230, 330 and a convex surface 232, 332. For the reasonsdiscussed in detail later, one of the flutes 210, 310 of each stalk rollhas a straight outer edge and is hereinafter referred to as the “cuttingflute” (not visible in FIGS. 7 and 8). The outer edges 214, 314 of theother remaining flutes 210, 310 are serrated resulting in a plurality ofpointed teeth 216, 316 extending along their lengths, each of theseserrated flutes is hereinafter referred to as a “puncturing flute”.

Continuing to refer to FIGS. 7-8 in combination with FIGS. 24-26, thestalk rolls 200, 300 are closely spaced laterally so that the outeredges 214, 314 of the radially extending flutes 210, 310 overlap oneanother as they rotate. As such, the stalk rolls are timed so that asthey rotate past one another, the outer edges 214, 314 of the flutes210, 310 are received between the opposing flutes of the opposing stalkroll. Additionally, as best illustrated in FIGS. 8 and 9, the teeth 216,316 of the respective stalk rolls 200, 300 are longitudinally translatedor offset from one another so that as the stalk rolls rotate, theirrespective teeth are not tip to tip, but are instead aligned so theteeth will mesh with each other wherein the tips of the teeth arereceived in the valleys between the opposing teeth of the opposing stalkroll as they rotate past one another.

The cylindrical body 204, 304 includes a flared rearward end 220, 320.The flared ends 220, 320 mate with the flared ends of the correspondingdrive shafts of the row unit assembly 30. The flutes 210, 310 areblunted and taper into the flared ends. The flared ends and bluntedflutes may help the smallest diameter portions of the cornstalk towardthe tassel to be crushed and chopped in the same manner as the largerdiameter portions of the cornstalk near the base as described in moredetail below.

FIGS. 10-16 illustrate an embodiment of the first stalk roll 200. Asbest illustrated in FIG. 13, the first stalk roll 200 includes tenflutes 210 identified by reference numerals 210-1 to 210-10. The cuttingflute is identified by reference numeral 210-10 and the remainingpuncturing flutes identified by reference numerals 210-1 to 210-9. Asbest illustrated in FIGS. 11 and 14-16, each tooth 216 of the puncturingflutes 210-1 to 210-9 includes a cup 234 in its concave surface 230. Thecup 234 smoothly transitions from a shallow depression near the base 212and at the outer edge 214 toward its deepest point at the middle of theconcave surface 230. The cup 234 also smoothly transitions from thesides of each tooth toward the middle, thereby forming a cupped tooth.

As best shown in FIGS. 10 and 13 and 15, at the interface of the nose202 and body 204, each of the two flights 206, 208 transitions without abreak into the flutes 210-2 and 210-7. As best shown in FIGS. 10, 14 and15, two of the flutes 210-4 and 210-9 extend a short distance forwardlybeyond the cylindrical body 204 and taper into the nose 202 in the samehelical direction as the flights 206, 208. The forward ends of theflutes 210 which do not transition into the nose 202 are stepped orstaggered with respect to one another as indicated by horizontaldimension lines “a”, “b” in FIGS. 14 and 15.

FIGS. 17-23 separately illustrate an embodiment of the second stalk roll300. Referring to FIG. 20, similar to the first stalk roll 200, thesecond stalk roll 300 200 includes ten flutes 310 identified byreference numerals 310-1 to 310-10. The cutting flute is identified byreference numeral 310-10 and the remaining puncturing flutes identifiedby reference numerals 310-1 to 310-9. However, unlike the teeth 216 ofthe first stalk roll 200, the teeth of the second stalk roll are notcupped. Comparing FIGS. 14 and 21, it should also be appreciated thatthe cupped teeth 216 of the first stalk roll 200 have a much morerounded outer edge and shallower valley between the teeth than the moresharply rounded and deeper valleyed teeth 316 of the second stalk roll300.

Also, similar to the first stalk roll 200, the flights 306, 308transitions without a break into two flutes 310-1 and 310-6. ComparingFIGS. 13 and 20, it should be appreciated that the flight-to-flutetransitions for the second stalk roll 300 are rotated one flutecounter-clockwise the with respect to the first stalk roll 200 (atflutes 210-2 and 210-7) of to avoid interference between the flights206, 208 and 306, 308 as they rotate past one another. Referring toFIGS. 21 and 22, two of the flutes 310-4 and 310-9 extend a shortdistance forwardly beyond the cylindrical body 304 and taper into thenose 302 in the same helical direction as the flights 306, 308 in thesame manner as in the first stalk roll 200. The forward ends of theflutes 310 which do not transition into the nose 302 are also stepped orstaggered with respect to one another as indicated by horizontaldimension lines “c”, “d” in FIGS. 21 and 22.

It has been found that stalk rolls with the foregoing flight-to-flutetransition and the stepped flute ends improves capturing of thecornstalks 16 between the flights 206, 208 and 306, 308 of the stalkrolls 200, 300 and effectively move the cornstalks 16 between thecylindrical bodies 204, 304 of the stalk rolls 200, 300 for crushing andshearing by the flutes 210, 310 thereby minimizing the problemsencountered with prior art stalk rolls in which the cornstalks stall orhesitate before being pulled between the cylindrical bodies.

In use, as shown in FIGS. 24-26, the stalk rolls 200 rotate in oppositedirections as indicated by arrows 120. The stalk rolls 200, 300 arelaterally spaced such that their respective flutes 210, 310 overlap asthey rotate past one another at about the 3 o'clock and 9 o'clockpositions as shown. As previously discussed, the position and rotationof the flutes 210, 310 are timed so the flutes do not make contact withone another as they rotate. The cutting flutes 210-10, 310-10 of eachstalk roll 200, 300 are also oriented with respect to one another sothat they come together in overlapping relation at about the 3 o'clockand 9 o'clock positions, respectively.

In operation, it should be appreciated that the teeth 216, 316 of thepuncturing flutes 210-1 to 210-9 and 310-1 to 310-9 punch into, punctureand/or pulverize the tough fibrous cornstalks as they rotate through thecornstalk which is desirable for the reasons identified below. However,as shown in FIG. 25, when the cutting flutes 210-10, 310-10 rotatethrough the cornstalk, the straight edge 214, 314 promotes shearing ofthe cornstalk by cutting through the cornstalk from each directionproducing chopped cornstalk sections 16 a which are approximately six toeight inches in length with each rotation of the cutting flutes 210-10,310-10.

It has been found that cornstalk sections that are six to eight inchesin length are more easily swept aside by the row cleaners of the planterduring the next planting season resulting in a furrow and seed bed freeof crop residue.

Through testing it has also been found that the cups 234 and moreblunted configuration of the teeth 216 of the first stalk roll 200 whichmesh with the sharper and deeper valleyed configuration of the teeth 316of the second stalk roll 300 promote horizontal and vertical fracturingof the cornstalk.

Accordingly, the stalk roll assembly 100 produces crop residue that issufficiently fractured and pulverized to promote uniform decompositionwhile still having enough integrity to keep the pulverized stalksections together so it remains the ideal length for being easily sweptaside by row cleaners during the next planting season. The more uniformdecomposition may result in a more uniform release of nitrogenthroughout the life of the next crop and reduce nitrogen immobilizationduring the critical early growing stages of the next season's crop.

In an alternative embodiment, rather than the stalk roll assembly 100being comprised of one each of the first and second stalk rolls 200,300, it should be appreciated that the stalk roll assembly 100 may becomprised of a pair of first stalk rolls 200 (i.e., each configured withthe more blunted or rounded cupped teeth 216). Alternatively, the stalkroll assembly 100 may be comprised of a pair of second stalk rolls 300(i.e., each configured with the more sharply rounded teeth 316). Itbeing understood that in such embodiments where a pair of stalk rolls200, 300 are used, one of the stalk rolls comprising the pair would haveoppositely twisting helical flights as the other, and theflight-to-flute transition would be rotated from the other stalk rollcomprising the pair for the reasons identified above.

FIG. 27 shows another embodiment of a stalk roll assembly 1000comprising first and second adjacently spaced stalk rolls 1200, 1300which may form part of a row unit 30 of an OEM or as a replacement stalkroll assembly for purposes of retrofitting an OEM row unit 30. As withthe previously described embodiment 100, in this embodiment 1000 thestalk rolls 1200, 1300 are removably secured in a conventional manner todrive shafts (not shown) which extend forwardly from a frame member 31of the row unit assembly 30.

In operation, each of the stalk rolls 1200, 1300 rotate about theirrespective longitudinal axis in the direction indicated by arrow 120. Aswith the previously described embodiment 100, in this embodiment 1000,the stalk rolls 1200, 1300 are configured to cooperate to achieve highthroughput of the cornstalks, leaves, husks, etc., while also ensuringthat the cornstalks are crushed along their length in more than onedirection and chopped in lengths preferably between six to eight inchesin length.

Consistent with the previously described embodiment 100, in thedescription of this alternative embodiment 1000, the common features ofboth stalk rolls 1200, 1300 are described together with referencenumerals in the 1200-series referring to the feature of the first stalkroll 1200 and reference numerals in the 1300-series referring to thefeatures of the second stalk roll 1300.

Each stalk roll 1200, 1300 has a frusto-conical nose 1202, 1302 whichtransitions into an elongated substantially cylindrical body 1204, 1304.The nose 1202, 1302 includes a pair of flights 1206, 1208 and 1306, 1308which extend helically rearwardly toward the cylindrical body 1204,1304. It should be appreciated that the helical direction of the flightsof the respective stalk rolls are opposite one another such that whenthe stalk rolls 1200, 1300 rotate in the direction indicated by arrows120, the flights will cooperate to draw the cornstalks rearwardly towardand between the cylindrical bodies 1204, 1304 of the adjacently disposedstalk rolls 1200, 1300.

Each cylindrical body 1204, 1304 includes a plurality of flutes 1210,1310 extending radially outwardly and spaced around the circumference ofthe body 1204, 1304 and which extend along the length of the body 1204,1304 in substantially parallel relation. As best illustrated in FIG. 27,unlike the first embodiment 100, in this embodiment 1000, not all of theflutes 1210, 1310 are equidistantly spaced around the circumference ofthe body 1204, 1304.

Each of the flutes 1210, 1310 are wide at their base 1212, 1312 and getprogressively narrower as they curve or hook toward the outer edge 1214,1314 resulting in concave surface 1230, 1330 and a convex surface 1232,1332. Additionally, unlike the first embodiment 100, in this embodiment1000, half of the flutes 1210, 1310 are oriented to curve or hook towardthe direction of rotation of the stalk roll (designated by arrow 120)and half of the flutes 1210, 1310 are oriented to curve or hook awayfrom the direction of rotation of the stalk roll. Thus, as bestillustrated in FIG. 27, each stalk roll 1200, 1300 has two flutes withtheir convex surfaces 1232, 1332 oriented back-to-back.

Also, unlike the previous embodiment 100 in which each stalk roll 200,300 had ten flutes 210, 310, in this alternative embodiment 1000, eachstalk roll 1200, 1300 includes eight flutes 1210, 1310 identified byreference numerals 1210-1 to 1210-8 and 1310-1 to 1310-8, respectively.Also unlike the previous embodiment 100 in which each stalk roll 200,300 included only one “cutting flute”, in this embodiment 1000, eachstalk roll 1200, 1300 include two “cutting flutes” having straight outeredges. In the first stalk roll 1200, the cutting flutes are identifiedby reference numeral 1210-1 and 1210-5. Likewise in the second stalkroll 1300, the cutting flutes are identified by reference numeral 1310-1and 1310-5. As best illustrated in FIG. 27, one of the cutting flutes1210-1, 1310-1 of each of the stalk rolls 1200, 1300 is oriented tocurve or hook away from the direction of rotation (designated by arrow120) of the stalk roll 1200, 1300 and the other cutting flute 1210-5,1310-5 of each of the stalk rolls 1200, 1300 is oriented to curve orhook toward the direction of rotation of the stalk roll 1200, 1300. Theremaining six flutes of each stalk roll 1200, 1300 are “puncturingflutes” each having a serrated edge forming a plurality of spaced teeth1216, 1316 along its length. The puncturing flutes of the first stalkroll 1200 are identified by reference numerals 1210-2, 1210-3, 1210-4,1210-6 and 1210-7. Likewise, the puncturing flutes of the second stalkroll 1300 are identified by reference numerals 1310-2, 1310-3, 1310-4,1310-6 and 1310-7.

As best illustrated in FIG. 27, the stalk rolls 1200, 1300 are closelyspaced laterally so that the outer edges 1214, 1314 of the radiallyextending flutes 1210, 1310 overlap one another as they rotate. As such,the stalk rolls are timed so that as they rotate past one another, theouter edges 1214, 1314 of the flutes 1210, 1310 are received between theopposing flutes of the opposing stalk roll. As in the previousembodiment, the teeth 1216, 1316 of the respective stalk rolls 1200,1300 are longitudinally translated or offset from one another so that asthe stalk rolls rotate, their respective teeth are not tip to tip, butare instead aligned so the teeth will mesh with each other wherein thetips of the teeth are received in the valleys between the opposing teethof the opposing stalk roll as they rotate past one another.

Unlike the first embodiment 100 in which the puncturing flutes of thefirst stalk roll 200 had only cupped teeth 216 (i.e., more rounded teethwith a shallow valley between teeth, with each tooth having anindentation or cup 234 in the concave surface 230) and whereas thesecond flute 300 had only non-cupped teeth 316 (i.e., more sharplyrounded teeth with deeper valley between teeth with no indentation inthe concave surface 330); in this alternative embodiment 1000, eachstalk roll 1200, 1300 includes both a set of cupped teeth 1216A, 1316Aand a set of non-cupped teeth 1216B, 1316B. In each of the respectivestalk rolls 1200, 1300, the cupped teeth 1216A, 1316A, havingindentations or cups 1234, 1334 are oriented to curve or hook away fromthe direction of rotation of the stalk roll (designated by arrow 120)and the non-cupped teeth 1216B, 1316B are oriented to curve or hooktoward the direction of rotation of the stalk roll.

As best illustrated in FIG. 27, the respective stalk rolls are orientedso that the cupped teeth 1216A of the first stalk roll 1200 will rotatethrough the corn stalk in close relation with the non-cupped teeth 1316Bof the second stalk roll 1300. Likewise, therefore, the non-cupped teeth1216B of the first stalk roll 1200 will rotate through the corn stalk inclose relation with the cupped teeth 1316A of the second stalk roll1300.

The cylindrical body 1204, 1304 of each stalk roll 1200, 1300 includes aflared rearward end 1220, 1320. The flared ends 1220, 1320 mate with theflared ends of the corresponding drive shafts of the row unit assembly30. The flutes 1210, 1310 are blunted and taper into the flared ends.The flared ends and blunted flutes may help the smallest diameterportions of the cornstalk toward the tassel to be crushed and chopped inthe same manner as the larger diameter portions of the cornstalk nearthe base as described in more detail below.

FIGS. 28-31 illustrate an embodiment of the first stalk roll 1200. Atthe interface of the nose 1202 and body 1204 of the first stalk roll1200, two flights 1206, 1208 transition without a break into the flutes1210-2 and 1210-6. Likewise, FIGS. 32-35 illustrate an embodiment of thesecond stalk roll 1300. At the interface of the nose 1302 and body 1304of the second stalk roll 1300, two flights 1306, 1308 transition withouta break into the flutes 1310-4 and 1310-8.

Comparing FIGS. 31 and 34, it should be appreciated that theflight-to-flute transitions for the second stalk roll 1300 are rotatedone flute clockwise the with respect to the first stalk roll 1200 toavoid interference between the flights 1206, 1208 and 1306, 1308 as theyrotate past one another. It has been found that stalk rolls with theforegoing flight-to-flute transition improves capturing of thecornstalks 16 between the flights 1206, 1208 and 1306, 1308 of the stalkrolls 1200, 1300 and effectively moves the cornstalks 16 between thecylindrical bodies 1204, 1304 of the stalk rolls 1200, 1300 for crushingand shearing by the flutes 1210, 1310 thereby minimizing the problemsencountered with prior art stalk rolls in which the cornstalks stall orhesitate before being pulled between the cylindrical bodies.

In use, as shown in FIG. 27, the stalk rolls 1200, 1300 rotate inopposite directions as indicated by arrows 120. The stalk rolls 1200,1300 are laterally spaced such that their respective flutes 1210, 1310overlap as they rotate past one another at about the 3 o'clock and 9o'clock positions as shown. As previously discussed, the position androtation of the flutes 1210, 1310 are timed so the flutes do not makecontact with one another as they rotate. The cutting flutes 1210-1,1210-5, 1310-1, 1310-5 of each stalk roll 1200, 1300 are also orientedwith respect to one another so that they come together in overlappingrelation at about the 3 o'clock and 9 o'clock positions, respectively.

In operation, it should be appreciated that the teeth 1216, 1316 of thepuncturing flutes 1210-2, 1210-3, 1210-4, 1210-6, 1210-7, 1210-8 and1310-2, 1310-3, 1310-4, 1310-6, 1310-7, 1310-8 punch into, punctureand/or pulverize the tough fibrous cornstalks as they rotate through thecornstalk which is desirable for the reasons identified above. When thecutting flutes 1210-1, 1210-5, 1310-1, 1310-5 rotate through thecornstalk, the straight edge 1214, 1314 promotes shearing of thecornstalk by cutting through the cornstalk from each direction producingchopped cornstalk sections which are approximately six to eight inchesin length with each rotation.

As with the previous embodiment 100, it has been found that thisembodiment 1000, produces cornstalk sections that are six to eightinches in length which are more easily swept aside by the row cleanersof the planter during the next planting season resulting in a furrow andseed bed free of crop residue.

Through testing it has also been found that when the cups 1234 and moreblunted configuration of the cupped teeth 1216A, 1316A of the first andsecond stalk rolls 1200, 1300 mesh with the sharper and deeper valleyedconfiguration of the teeth 1316B, 1216B of the opposing stalk roll 1300,1200, respectively, horizontal and vertical fracturing of the cornstalkis promoted.

Accordingly, the stalk roll assembly 1000 produces crop residue that issufficiently fractured and pulverized to promote uniform decompositionwhile still having enough integrity to keep the pulverized stalksections together so it remains the ideal length for being easily sweptaside by row cleaners during the next planting season. The more uniformdecomposition may result in a more uniform release of nitrogenthroughout the life of the next crop and reduce nitrogen immobilizationduring the critical early growing stages of the next season's crop.

The stalk rolls 200, 300, 1200, 1300 may be made of ductal iron fusedwith a polymer or any other suitable material combination. The stalkrolls 200, 300, 1200, 1300 may be forged or machined as a single pieceor may be made from a plurality of separate components secured together.Generally, the stalk rolls 200, 300, 1200, 1300 are comprised of a shellto which a machine specific internal component is pressed or assembledfor mating engagement with a complimentary drive shaft of the row unitassembly on the cornhead.

Various modifications to the embodiments of the apparatus, and thegeneral principles and features of the system and methods describedherein will be readily apparent to those of skill in the art. Thus, theinvention is not to be limited to the embodiments of the apparatus,system and methods described above and illustrated in the drawingfigures, but is to be accorded the widest scope consistent with thespirit and scope of the appended claims.

1. A stalk roll assembly for a header of a combine harvester,comprising: a first stalk roll rotating in a first rotational directionabout a longitudinal axis, the first stalk roll having a firstcylindrical body, a first plurality of flutes spaced around andextending radially outwardly from the first cylindrical body, each ofthe first plurality of flutes extending along a length of the firstcylindrical body, at least one of the first plurality of flutescomprising a cutting flute having a straight outer edge, at least one ofanother of the first plurality of flutes comprising a puncturing flutehaving an outer edge with a plurality of longitudinally spaced teethspaced; a second stalk roll rotating in a second rotational directionopposite the first rotational direction, the second stalk roll having asecond cylindrical body, a second plurality of flutes spaced around andextending radially outwardly from the second cylindrical body, each ofthe second plurality of flutes extending along a length of the secondcylindrical body, at least one of the second plurality of flutescomprising a cutting flute having a straight outer edge, at least one ofanother of the second plurality of flutes comprising a puncturing flutehaving an outer edge with a plurality of longitudinally spaced teeth;wherein the second stalk roll is spaced a distance laterally withrespect to said first stalk roll such that the outer edges of the firstplurality of flutes laterally overlap with outer edges of the secondplurality of flutes as the first and second stalk rolls rotate; whereinat least one of the first plurality of flutes are curved in a directiontoward the first rotational direction and at least one of the secondplurality of flutes are curved in a direction away from the secondrotational direction.
 2. The stalk roll assembly of claim 1, wherein atleast some of the first plurality of flutes have a concave surface and aconvex surface and at least some of the second plurality of flutes havea concave surface and a convex surface.
 3. The stalk roll assembly ofclaim 2, wherein some of the first plurality of flutes are curved in adirection toward the first rotational direction and some of the firstplurality of flutes are curved in a direction away from the firstrotational direction, and wherein some of the second plurality of flutesare curved in a direction toward the second rotational direction andsome of the second plurality of flutes are curved in a direction awayfrom the second rotational direction.
 4. The stalk roll assembly ofclaim 2, wherein the concave surface includes an indentation forming acup.
 5. The stalk roll assembly of claim 3, wherein the concave surfaceof the first plurality of flutes curved in the direction away from thefirst rotational direction include an indentation forming a cup andwherein the concave surface of the second plurality of flutes curved inthe direction away from the second rotational direction include anindentation forming a cup.
 6. The stalk roll assembly of claim 1,further comprising: a first frusto-conical nose transitioning into thefirst cylindrical body, the first frusto-conical nose including a firstpair of flights extending helically along the first frusto-conical nose;and a second frusto-conical nose transitioning into the secondcylindrical body, the second frusto-conical nose including a second pairof flights extending helically along the second frusto-conical nose. 7.The stalk roll assembly of claim 6, wherein at least one of the firstplurality of flutes extends forwardly onto the first frusto-conical nosebetween the first pair of helical flights, and wherein at least one ofthe second plurality of flutes extends forwardly onto the secondfrusto-conical nose between the second pair of helical flights.
 8. Thestalk roll assembly of claim 7, wherein one of the first plurality offlutes circumferentially adjacent to the at least one forwardlyextending flute of the first plurality of flutes terminates rearwardlyof another adjacent one of the first plurality of flutes, and whereinone of the second plurality of flutes circumferentially adjacent to theat least one forwardly extending flute of the second plurality of flutesterminates rearwardly of another adjacent one of the second plurality offlutes.
 9. The stalk roll assembly of claim 1, wherein each of the firstand second plurality of flutes comprises ten flutes.
 10. The stalk rollassembly of claim 1, wherein each of the first and second plurality offlutes comprises eight flutes.
 11. The stalk roll assembly of claim 1,wherein each of the first and second plurality of flutes include twocutting flutes.
 12. The stalk roll assembly of claim 9, wherein each ofthe first and second plurality of flutes include two cutting flutes. 13.The stalk roll assembly of claim 11, wherein one of the two cuttingflutes has a convex surface that curves away from a convex surface of anadjacent flute.
 14. The stalk roll assembly of claim 1, wherein each ofthe another of the first and second plurality of flutes is a puncturingflute.
 15. The stalk roll assembly of claim 10, wherein each of theanother of the first and second plurality of flutes is a puncturingflute.
 16. The stalk roll assembly of claim 1, wherein each of thelongitudinally spaced teeth of the puncturing flutes of the first andsecond plurality of flutes have a tip and whereby a valley is formedbetween longitudinally adjacent tips.
 17. The stalk roll assembly ofclaim 16, wherein the tips of the teeth of the puncturing flutes of thefirst and second stalk rolls are longitudinally offset such that thetips of the teeth of the puncturing flutes of the second stalk rollextend into the valleys between the adjacent tips of the puncturingflutes of the first stalk roll as the first and second stalk rollsrotate.
 18. A method of processing cornstalks during harvestingoperations, comprising: moving a stalk roll assembly along a row ofcornstalks in a field, the stalk roll assembly including a first stalkroll rotating in a first direction and a second stalk roll rotating in asecond direction opposite the first direction; the first stalk rollhaving a first cylindrical body, a first plurality of flutes spacedaround and extending radially outwardly from the first cylindrical body,each of the first plurality of flutes extending along a length of thefirst cylindrical body, at least one of the first plurality of flutescomprising a cutting flute having a straight outer edge, at least one ofanother of the first plurality of flutes comprising a puncturing flutehaving an outer edge with a plurality of longitudinally spaced teethspaced; the second stalk roll having a second cylindrical body, a secondplurality of flutes spaced around and extending radially outwardly fromthe second cylindrical body, each of the second plurality of flutesextending along a length of the second cylindrical body, at least one ofthe second plurality of flutes comprising a cutting flute having astraight outer edge, at least one of another of the second plurality offlutes comprising a puncturing flute having an outer edge with aplurality of longitudinally spaced teeth; wherein at least one of thefirst plurality of flutes are curved in a direction toward the firstrotational direction and at least one of the second plurality of flutesare curved in a direction away from the second rotational direction;wherein the puncture flutes of the first and second stalk rolls crushthe cornstalks along their length in more than one direction as thepuncture flutes rotate through the cornstalks; and wherein the cuttingflutes of the first and second stalk rolls are oriented and timed withrespect to one another such that the cutting flutes come together inoverlapping relation cutting the cornstalks in lengths between about sixto about eight inches with each rotation of the cutting flutes.
 19. Themethod of claim 18, wherein at least some of the first plurality offlutes have a concave surface and a convex surface and at least some ofthe second plurality of flutes have a concave surface and a convexsurface.
 20. The method of claim 19, wherein some of the first pluralityof flutes are curved in a direction toward the first rotationaldirection and some of the first plurality of flutes are curved in adirection away from the first rotational direction, and wherein some ofthe second plurality of flutes are curved in a direction toward thesecond rotational direction and some of the second plurality of flutesare curved in a direction away from the second rotational direction. 21.The method of claim 19, wherein the concave surface includes anindentation forming a cup.
 22. The method of claim 20, wherein theconcave surface of the first plurality of flutes curved in the directionaway from the first rotational direction include an indentation forminga cup and wherein the concave surface of the second plurality of flutescurved in the direction away from the second rotational directioninclude an indentation forming a cup.
 23. The method of claim 18,wherein: the first stalk roll assembly includes a first frusto-conicalnose transitioning into the first cylindrical body, the firstfrusto-conical nose including a first pair of flights extendinghelically along the first frusto-conical nose; and the second stalk rollassembly includes a second frusto-conical nose transitioning into thesecond cylindrical body, the second frusto-conical nose including asecond pair of flights extending helically along the secondfrusto-conical nose.
 24. The method of claim 23, wherein at least one ofthe first plurality of flutes extends forwardly onto the firstfrusto-conical nose between the first pair of helical flights, andwherein at least one of the second plurality of flutes extends forwardlyonto the second frusto-conical nose between the second pair of helicalflights.
 25. The method of claim 24, wherein one of the first pluralityof flutes circumferentially adjacent to the at least one forwardlyextending flute of the first plurality of flutes terminates rearwardlyof another adjacent one of the first plurality of flutes, and whereinone of the second plurality of flutes circumferentially adjacent to theat least one forwardly extending flute of the second plurality of flutesterminates rearwardly of another adjacent one of the second plurality offlutes.
 26. The method of claim 18, wherein each of the first and secondplurality of flutes comprises ten flutes.
 27. The method of claim 18,wherein each of the first and second plurality of flutes comprises eightflutes.
 28. The method claim 18, wherein each of the first and secondplurality of flutes include two cutting flutes.
 29. The method of claim26, wherein each of the first and second plurality of flutes include twocutting flutes.
 30. The method of claim 28, wherein one of the twocutting flutes has a convex surface that curves away from a convexsurface of an adjacent flute.
 31. The method of claim 18, wherein eachof the another of the first and second plurality of flutes is apuncturing flute.
 32. The method of claim 27, wherein each of theanother of the first and second plurality of flutes is a puncturingflute.
 33. The method of claim 18, wherein each of the longitudinallyspaced teeth of the puncturing flutes of the first and second pluralityof flutes have a tip and whereby a valley is formed betweenlongitudinally adjacent tips.
 34. The method of claim 33, wherein thetips of the teeth of the puncturing flutes of the first and second stalkrolls are longitudinally offset such that the tips of the teeth of thepuncturing flutes of the second stalk roll extend into the valleysbetween the adjacent tips of the puncturing flutes of the first stalkroll as the first and second stalk rolls rotate.